Devices, systems, and methods for multi-projector three dimensional printing

ABSTRACT

Devices, systems, and/or methodologies are provided for three dimensional printing, for example, additive manufacturing, wherein an array of energy patterning (e.g., light patterning) modules are used in conjunction with an automated positional control system to coordinate implementation of patterning modules of the array. Implementation of the array can be controlled by a sensory feed-back.

CROSS-REFERENCE TO RELATED APPLICATIONS

This utility patent application is a divisional application of, andclaims the benefit of priority to, U.S. Non-provisional application Ser.No. 16/835,182, filed on Mar. 30, 2020, entitled DEVICES, SYSTEMS, ANDMETHODS FOR MULTI-PROJECTOR THREE DIMENSIONAL PRINTING, which claims thebenefit of priority to U.S. Provisional Patent Application No.62/826,361, filed on Mar. 29, 2019, entitled METHOD AND SYSTEM FORMETHODOLOGIES AND HARDWARE FOR MULTI-PROJECTOR THREE DIMENSIONALPRINTING, the contents of each of which are incorporated herein byreference, in their entireties.

SUMMARY

Disclosed embodiments relate to devices, systems, and methodologies forthree dimensional printing, for example, additive manufacturing, whichcan include a StereoLithographic Approach (SLA) and/or Digital LightPatterning (DLP) for three dimensional printing.

In accordance with at least some disclosed embodiments, an array ofenergy patterning (e.g., light patterning) modules may be used in a 3Dprinting methodology.

In accordance with at least some disclosed embodiments, each patterningmodule may include a multi-axis, micro-positioning system operating inconjunction with an energy patterning system including a projector.

In accordance with at least some disclosed embodiments, the projectionsystem and/or micro-positioner may participate in a feed-back controlloop for automated alignment of the energy patterning system to generatea continuous display area.

In accordance with at least some disclosed embodiments, each patterningmodule may contain an on-board micro-computer which is responsible forreceiving and distributing commands to the energy patterning systemand/or the micro-positioning system from a local or remote host. Thecommunication between the micro-computer and the host may be (i) wiredor wireless, (ii) encrypted, and (iii) bi-directional.

In accordance with at least some disclosed embodiments, themicro-computer may receive commands/data which are sent to thepatterning module to control energy output (both pattern and intensity)of the projection of the energy patterning system. The micro-positionermay receive commands/data which are used to adjust the location of thepatterning module along with the projector within the patterning module.

BRIEF DESCRIPTION OF THE DRAWINGS

An exemplary embodiment is shown in the drawings and is explained indetail below with reference to the figures. In the drawings:

FIGS. 1-4 provide various views of an illustrative example of apatterning module designed in accordance with disclosed embodiments.

FIGS. 5-6 provide various views of an illustrative example, of a singlepatterning module mounted to an optical board as well as a 3×3 array ofpatterning modules (nine in total) mounted on an optical board forcomparison and illustration of the exemplary combination of modules thatmay be used in accordance with disclosed embodiments.

FIGS. 7-8 illustrate example of alignment operations aligning the fieldof view from two separate projectors with mounting that does not resultin perfect alignment there between.

FIGS. 9 and 10 illustrates an example of alignment operations ofpatterning modules in a 3×3 array in accordance with disclosedembodiments.

FIG. 11 illustrates a top-down depiction of optical modules with alignedfields-of-view in accordance with at least one disclosed embodiment forprinting a large diameter gasket.

FIG. 12 illustrates another top-down depiction of optical modules withaligned fields-of-view in accordance with at least one disclosedembodiment for printing a large diameter gasket.

FIGS. 13-17 illustrate views of another optical modules in accordancewith the present disclosure.

FIG. 18 illustrates a perspective view of an additive manufacturingsystem including a base mount having the optical module of FIGS. 13-17mounted thereon.

FIG. 19 illustrates a perspective view of the additive manufacturingsystem of FIG. 18 showing the base mount having a plurality of opticalmodules of FIGS. 13-17 mounted thereon.

DETAILED DESCRIPTION

Conventionally, the StereoLithographic Approach (SLA) for additivemanufacturing presents unique capabilities and technical opportunitiesover competing technologies. This is because SLA can deliver highprint-speeds, while generating objects from a library of robustmaterials.

Central to the printing configuration for SLA, is the “light-engine,” orprojector, which is responsible for patterning light/energy to drivepolymerization reactions of photo-sensitive liquid resins in themanufacturing process. The spectrum of light projected, power-density ofthe projected light, and the rate in which the light can be patternedall govern the capabilities of the additive manufacturing device, orprinter, that utilizes the light engine.

For the purposes of this disclosure, the term “energy” is used to referto energy measured in various forms including, but not limited to,radiated energy, for example light, both visible and not visible. Thus,it should be understood that, the application of “energy” is meant toinclude, and not be limited to the application of heat (thermal), light(radiant), electrical energy, magnetic energy, etc.

There exist two common routes to light/energy patterning in additivemanufacturing devices. The first utilizes a laser beam, directed over atwo-dimensional (2D) plane with a series of motorized mirrors (e.g.,mirror galvanometers, also called “galvos”, or resonance scanners), totrace out a 2D cross-sectional image of a net-shape to be printed. A

Alternatively, Digital Light Processing (DLP) chips can be used inclassical projector configurations to pattern microscopic pixels acrossthe 2D plane, wherein, each pixel is updated on an internal clockfrequency.

Ultimately, both light/energy patterning techniques have limitationsregarding their ability to scale to larger 2D print beds.

In the case of the scanning laser beams, as the distance the beams spanincreases, there is a corresponding loss in lateral resolution of thebeam cross section. This results in a corresponding loss of resolutionin a printed object. Moreover, as a result of using a fixed scan speed,the increase size results in the 2D display frequency becoming quiteslow; this limits the vertical print rate of any 3D printer configuredusing scanning laser beams.

In the case of the DLP based patterning technique, projection lenses maybe used to cover a larger 2D area. However, the limited pixel density ofconventionally available DLP chips in the market similarly limits thetechnical effect of this configuration. More specifically, with thelimited pixel density, the projection over a larger area simply resultsin a larger projected pixel and a coarser 3D printed object.

An additional limitation of the DLP approach is that, when scaled tolarger areas, there is a resulting limitation on projection powerdensity. This is because, with less photons per unit area beingdelivered, the chemical reactions responsible for the print mechanismrun slower and become a bottle neck in the print process. Conventionalapproaches to address this issue have included use of multipleprojectors to cover a larger area. Such an approach has been used fordecades by lighting specialists in the entertainment industry with bothDLP and laser scanning systems. In this way, The projection area of eachindependent light engine can be stitched together to generate a largeimage. Indeed, conventionally, an array of light engines has been shownto be successful for performing 3D printing (for example, as disclosedin PCT Publication WO 2015200173).

However, in implementation, combining the effects of each independentlight engine requires a methodology and equipment that enable tilingthese projectors in an infinite means. Although mirrors can be used toeasily tile two to four projectors into an array, beyond a certainpoint, the conventionally know use of mirrors becomes impractical, ifnot impossible, to scale.

Accordingly, new designs are required to tile a larger number of lightpatterning modules together. Presently disclosed embodiments providehardware and software implemented systems that enable automaticalignment and stitching together of micro-patterning modules (i.e.,pixel sizes below 500 μm) with high lateral precision.

It should be understood that, while disclosed embodiments enabletechnical utility to tile DLP based micro-projectors for SLA printingapplications (together, referred to, herein, as “DLP-SLA” printingapplications), the hardware and techniques described herein also havetechnical utility in application to other forms of 3D printing, in whichmultiple energy patterning modules may be used.

For example, the innovations disclosed herein have particular utilityfor application to Selective Laser (SL) SLA (often called SL-SLA), orSelective Laser Sintering (SLS), in which multiple laser modules mightbe tiled so as to cover a larger area with enhanced resolution.

It should also be understood that the hardware and correspondingsoftware described herein are unique in both technical structure andfunctionality from those used in conventional entertainmentapplications, in which the 2D projection plane is often substantiallylarger than the hardware footprint by an order of magnitude (forexample, a theatrical performance stage, movie viewing screen, buildingfaçade, etc.).

Rather, in the technological and industrial manufacturing context of 3Dprinting, often, the 2D projection plane is smaller than the footprintof the projection/patterning hardware. Thus, disclosed embodimentsutilize miniaturized projection hardware and corresponding alignmentsystems for such hardware to conform the system to a footprint smallerthan a desired projection domain.

Such an implementation enables the ability to more effectively scale tolarger 2D print beds. As alluded to above, the number of patterningmodules in an optical system grows, the precise alignment of thosemodules becomes more challenging. More specifically, conventional,manual alignment systems used in projection systems with a small numberof projectors immediately become impractical. For example, in atwo-projector system, adjustments to a single projector via a manualmicro-manipulator are unlikely to interfere with the neighboringprojector. This is because the manipulator is un-obstructed from all butone direction.

However, when there is an array of 10-100 micro-projection systems,precision alignment becomes a great technical challenge and obstacle toeffective implementation because there is no practical way to adjust oneof the micro-projections system within the array manually withoutcausing significant disruptions to the surrounding micro-projectionsystems.

To eliminate this impediment, disclosed embodiments provide a systemwith micro-projection patterning modules that utilize wirelesscommunication to transmit data relating to both positional control dataand projection data. The technical effect of such transmission of bothpositional and projection data can be recognized in an example, whereina large array, e.g., 10-100 projectors; wireless transmission from acentralized controller greatly reduces the number of wires/connectionlines necessary to implement positional coordination and supply ofprojection data for patterning. Although not shown, such a centralizedcontroller may be implemented using one or more computer processors andassociated hardware for communicating wirelessly with each of aplurality of projection modules.

In accordance with the disclosed embodiments, each patterning module maybe provided with only a single fixed wire to power for operation.Accordingly, all other control, content and operation information may beconveyed from a centralized controller wirelessly to the patterningmodules.

Increased flexibility, ease of use and decreased maintenance time resultfrom the highly-modular nature of systems provided in accordance withthe disclosed embodiments. If a projector in a single patterning modulein a 10×10 projector array (i.e., one of 100 projectors) has a failure,that patterning module can be removed and replaced with an operationalpatterning module without interfering with the remainder of theprojection system.

Additionally, this modularity enables the ability to position projectorsinto arrays of varying aspect ratios or even non-continuous domains asnecessary for a given application. For example, instead of 100projectors being in a 10×10 array, the array could be in a 1×100 array,a 2×50 array, a 4×25 array, 5×20 array, etc.

As explained above, in accordance with at least some disclosedembodiments, an array of energy patterning (e.g., light patterning)modules may be used in a 3D printing methodology. In SLA 3D printing,the resolution of the x-y plane is often limited by the opticalprojection system which delivers light/energy to the build interface.The ability to tile multiple projection systems into a large,high-resolution array is often limited by the ability to align multiplemicro-projection systems laterally.

To accomplish this, disclosed embodiments utilize a projection modulepackage volume that contains (i) the optical projection components, (ii)a data receiver, and (iii) an electronically controlledmicro-positioner; all of which must fit within the footprint of aprojected image. For example, for illustrative purposes, consider that,given a ‘coarse’ resolution of 100 um in conjunction with a 1080presolution DLP projection module, the cross-section of thisprojector/manipulator module may be limited to 4.25″×7.5″ laterally. Ifa higher resolution system is desired, such as a common standard of 50um, this area may decrease to −2.2″×3.8″. Given these small constraints,disclosed embodiments are directed at providing customized modules thatfulfill such required resolutions.

FIGS. 1-4 illustrate an example of a patterning module provided inaccordance with the disclosed embodiments. Those figures provide variousviews of a patterning module 100 and its constituent components. Asshown in FIGS. 1-4 , the patterning module 100 may include amicro-projector 110 which is configured and operates to pattern energy(for example, UV light via DLP). However, it should be understood thatthe micro-projector 110 may be implemented with one or more lasersoperating in conjunction with galvo mirrors or other conventionallyknown and commercially available or custom patterning/energy systems.

In accordance with at least one disclosed embodiment, the patterningmodules 100 disclosed herein may include a micro-projector that is anoff-the-shelf model (i.e., conventionally obtainable in an uncustomizedstate), which is then modified to project Ultra Violet (UV) light(required for photoinitiators used in the SLA printing processes). Thepatterning module 100 may also include a micro-computer 120, which iswirelessly coupled to, and receives commands from, a host computer(including, for example, positional and projection data) to controlpositioning and output of energy of the projector 100 to enablepatterning for 3D printing processes. Thus, in accordance with at leastsome disclosed embodiments, the micro-computer 120 may receivecommands/data which are sent to the patterning module 100 by the hostcomputer to control energy output (both pattern and intensity) of theprojection of the projector 110.

Micro-computer 120 may include any suitable micro-computing device, forexample, a micro-computing device defined as an electronic circuitconsisting of a processor/microprocessor, CPU, RAM, equipped forexternal communication (e.g., by wired Ethernet connection, wifi module,NFC, Bluetooth, NIR, optical, and/or any other suitable wired orwireless communications equipment, etc). Exemplary micro-computingdevices may falls below the size range of a standard lap-top or desktopcomputing device. Examples of suitable micro-computing devices mayinclude a Raspberry Pi, an Arduino board, an Intel ‘Stick’ or ‘NUC’computer, or any computing device with comparable volume or smaller tothose listed.

Micro-computer 120 and/or host computer may include suitable memoryand/or communications circuitry for implementing their disclosesoperations. Examples of suitable processors may include one or moremicroprocessors, integrated circuits, system-on-a-chips (SoC), amongothers. Examples of suitable memory, may include one or more primarystorage and/or non-primary storage (e.g., secondary, tertiary, etc.storage); permanent, semi-permanent, and/or temporary storage; and/ormemory storage devices including but not limited to hard drives (e.g.,magnetic, solid state), optical discs (e.g., CD-ROM, DVD-ROM), RAM(e.g., DRAM, SRAM, DRDRAM), ROM (e.g., PROM, EPROM, EEPROM, FlashEEPROM), volatile, and/or non-volatile memory; among others.Communication circuitry may include components for facilitatingprocessor operations, for example, suitable components may includetransmitters, receivers, modulators, demodulator, filters, modems,analog to digital converters, operational amplifiers, and/or integratedcircuits.

The patterning module 100 may also include a micro-positioner system 130driven by a combination of a plurality of stepper motors 140, forexample, three stepper motors. The stepper motors could be replaced byother actuating devices, such as pneumatic systems, dc motors, railsystems, etc. Each projector 110 may be mounted to a modified X-Y-Zpositioning stage. The axis of these stages may be modified to bemanipulated through the coordinated control and operation of theplurality of stepper motors (one for each axis). The micro-positioner130 may receive commands/data via the micro-computer 120; suchcommands/data which are used to adjust the location of the patterningmodule along with the projector within the patterning module 100.

The micro-projector 110, on-board, Wi-Fi enabled microcomputer 120, andmicro-positioner components 130, are collectively sized, positioned andfunction such that the cross-sectional area of the overall patterningmodule including those components is smaller than the projection fieldof a single micro-projector.

In accordance with the disclosed embodiments, each patterning module 100may include a multi-axis, micro-positioning system 130 operating inconjunction with an energy patterning system including a projector 110.More specifically, optomechanical hardware is provided which couplesmicro-projectors 110 included in patterning modules 100 withelectrically driven, multi-axis micro manipulators. When tiled together,these patterning modules 100, and their constituent micro projectors110, can be aligned to generate a high-resolution optical projectionsystem over an arbitrarily large print bed.

Likewise, each patterning module 100 may contain an on-boardmicro-computer 120 which is responsible for receiving and distributingcommands to the energy patterning system and the micro-positioningsystem 130 from a remote host (e.g., a centralized, computer implementedcontroller for the multi-projector system). The communication betweenthe micro-computer 120 and the host may include any one or more of (i)wired and/or wireless communications, (ii) encrypted and/or securedcommunications, and (iii) unidirectional and/or bi-directionalcommunications. In this way, disclosed embodiments provide a system withmicro-projection patterning modules 100 that utilize wirelesscommunication to transmit data relating to both positional control andprojection data. The technical effect of such transmission of bothpositional and projection data can be recognized in an example, whereina large array, e.g., 10-100 projectors; wireless transmission greatlyreduces the number of wires/connection lines necessary to implementpositional coordination and supply of projection data for patterning. Insome embodiments, wired and wireless communication may be implementedtogether, for example, with one or more modules 100 communicating withthe host computer by wired connection and one or more other modules 100communicating with the host computer by wireless connection.

The on-board microcomputer 120 is Wi-Fi enabled to receive positionalcommands, and translates these commands to motor driver instructions forcontrolling operation of a plurality of stepper motors 140 to cause theactuation and relocation of the projection module 100. Additionally, theon-board microcomputers 120 may be used to receive projection data fromthe common, remote host, which may be routed to the micro-projector 110to control the display output.

The communication between the centralized host computer and thepatterning modules may be encrypted, e.g., encryption of Scalable VectorGraphics (SVG) strings via algorithms such as AES (symmetric 128-bitencryption cypher) may be sent to each patterning module address toensure that the proper instructions are sent to each patterning modulein an array without risk (or with reduced risk) of tampering. In someembodiments, graphical vector strings may include any suitable form ofvector string definition, format, substance, etc., for example,projection data may represented by a series of vectors described in anysuitable string format, i.e., non-rasterized image. Likewise, encryptionof control and/or feedback data may be performed using cypher keysspecific to the overall multi-projector implemented additivemanufacturing device itself (this may be implemented, for example, usinga MAC address to position library); in this way, the x-y image planedata may be scrambled. Further, encryption may be based upon bufferingfrequency/speed scrambling the z-image stack data. Scrambling mayinclude misordering data (of the relevant axis) to delinearize theinformation.

The projection data can be formulated either to enable automatedalignment (e.g., projection of positional markers for feed-back control)or to enable projection of a sub-set of a larger 2D image beingdisplayed across the array for the purpose of 3D printing. Thus, inaccordance with at least one embodiment, the patterning modules 100 canproject a test-pattern at a build interface, which can be utilized forhigh-resolution alignment (i.e., on the resolution of a single pixeldepending on the resolution of an imaging sensor) through use of afeed-back control loop.

FIG. 5 illustrates an example of a single projector array 505 includinga single patterning module 100 mounted to an optical board 150. FIG. 6 ,illustrates an example of an array 605 of modules 100 arranged in a 3×3configuration for a total of nine projectors mounted on optical board150.

In accordance with at least some disclosed embodiments, the projectionsystem and/or micro-positioner may participate in a feed-back controlloop for automated alignment of the energy patterning system to generatea continuous display area. FIGS. 7-8 illustrate an example of alignmentoperations for the field of view 360, 360′ from two separatemicro-projectors 310, 310′ that are part of separate patterning modules300, 300′ positioned relative to one another on a mounting plate, i.e.,optical board. The combined field of view 360, 360′ of themicro-projectors 310, 310′ represents an applicable display area.

As can be seen in FIG. 7 , the mounting of the micro-projectors 310,310′ does not result in perfect alignment. The adjacent edges(longitudinal bottom edge of 360, and longitudinal top edge of 360′) ofthe fields of view 360, 360′ are spaced apart from each other. Thecorresponding lateral edges (right and left edges) of the fields of view360, 360′ are misaligned. In some embodiments, the adjacent fields ofview 360, 360′ may experience other aspects of misalignment, forexample, tilt such that corresponding longitudinal and/or lateral edgesare not parallel with each other. To the contrary, as illustrated inFIG. 8 , while the positioning of the micro-projectors 310, 310′ on themounting plate illustrated in FIG. 7 remains in the same position asthat illustrated in FIG. 7 (that is, out of perfect alignment) themicro-projectors 310 and their resultant field of view 360 may berepositioned in one or more of the x-y-z directions by themicro-positioner systems (such as micro-positioner system 130 using thestepper motors 140 under control of the on-board components illustratedin FIGS. 1-4 ) to create an aligned and continuous field of view 360,360′ having continuity at the adjacent edges of the fields of view 360,360′. The example in FIG. 8 shows continuous display by longitudinaledges corresponding exactly in position to eliminate a gap between thefields of view 360, 360′ such that the fields of view 360, 360′ contactand/or engage each other, and alignment between the correspondinglateral edges; however, in some applications continuous display may notrequire such alignment of lateral edges, for example, where theapplicable footprint of the build subject may be covered by staggered,adjacent fields of view. Similarly, in some applications, continuity ofadjacent edges may consider lateral edges contacting and/or engagingeach other, and the longitudinal edges may have relative positioning,whether aligned or staggered according to the particular application. Insome embodiments, continuous display may not require exact contact ofadjacent edges but may include reduction of the spacing between adjacentedges to a threshold spacing, for example, below 1 pixel width; althoughthe threshold spacing may be application specific, for example, withinany suitable range of pixel widths from 0.1 to 10 pixels (fordescriptive purposes, about 0.001 to about 0.10 inches).

Within the present disclosure, the field of view 360 of an individualmodule 100 is arranged to be larger than a footprint of the module 100.Referring briefly to FIG. 7 , the field of view 360 is larger than thefootprint 363 of the module 100 in the x-y plane. Likewise the field ofview 360′ is larger than the footprint of the corresponding module 100in the x-y plane. Referring briefly to FIG. 9 , each field of view ofeach individual module 100 of the array is larger than the footprint ofthe corresponding module. In the illustrative embodiment, the collectivefield of view of the array constituting a display area is larger thanthe collective footprint of the modules 100 of the array.

FIGS. 9-10 illustrate an example of a 3D printing system 400, in whichan array 405 of a plurality of patterning modules 410A, 410B, 410C,410A′, 410B′, 410C′, and 410A″, 410B″, 410C″ are aligned (e.g., a 3×3array of modules). As shown in FIGS. 9-10 , an observational sensor 420is configured to detect mis-alignment of positional indicator markers430 associated with the fields of view of each of the projectorsincluded in the patterning module array 405.

Based on the relative positioning of these positional indicator markers430 to their neighbors, the observational sensor 420 of the 3D printingsystem 400 can detect that a middle projection module 410B′ ismis-aligned and must be relocated, as illustrated by the arrow in FIG. 9. A translation may then be performed of the position of the middleprojection module 410B′ to affect, or perfect, the alignmentpositioning. FIG. 10 illustrates the resulting alignment after making ax-y plane movement using the micro-positioner and stepper motorsillustrated herein.

The observational sensor 420 may also include sensors and associatedcomputational and control software configured to recognize that spacingbetween positional indicator markers on a single projector (i.e., leftand right side of projection field of view) is either too large orsmall. This may be considered an indication that the patterning module(in this case, having a fixed focal length) is either under or overfocused. Based on that indication and its recognition, the computationand control software may make corresponding adjustments in the z-axisfor that projector. Observational sensor 420 may include image (e.g.,photo, video, thermal, infrared, UV, etc.), positional (e.g., radar,lidar, time-of-flight, etc), and/or other suitable sensor devices.

While certain illustrative embodiments have been described, it isevident that many alternatives, modifications, permutations andvariations will become apparent to those skilled in the art in light ofthe foregoing description. Accordingly, the various embodiments of, asset forth above, are intended to be illustrative, not limiting. Variouschanges may be made without departing from the spirit and scope of theinvention.

For example, as explained above, in accordance with disclosedembodiments. modularity enables the ability to position projectors intoarrays of varying aspect ratios or even non-continuous domains asnecessary for a given application, e.g., 100 projectors being in a 10×10array. Alternatively, if a large diameter tubular structure is desired,one potentially optimal arrangement of projectors may cover thefootprint of an annulus in which there is a discontinuity in the center,thus requiring no patterning modules in that location, as illustrated inFIG. 11-12 .

FIG. 11 illustrates a top-down depiction of optical modules with alignedfields-of-view (represented by black dashed lines). The desired objecthas a profile of an annulus, represented by the curved shading. Thisenables for the printing of this object with less optical module units,e.g., using 10 instead of 12 in a continuous array. These savings becomelarger when such a structure becomes larger. Thus, in implementationsuch an embodiment has particular technical utility in a scenariowherein the desire is to print a 3 foot outer-diameter gasket. It shouldbe understood, in that scenario, for such an embodiment implementation,the annuls would not need optical modules within its inner diameter tobe printed.

FIG. 12 illustrates a top-down depiction of optical modules with alignedfields-of-view (again represented by black dashed lines). In FIG. 12 ,the 2-D projection of the desired object, again represented by curvedshading, does not require a full array of 16 optical modules (i.e.,4×4). Again, in implementation such an embodiment has particulartechnical utility in a scenario wherein the desire is to print a large,non-circular gasket. It should be understood, in that scenario, for suchan embodiment implementation, it is possible to use 75% of theprojection modules that would otherwise be required; in doing so, thisimplementation drastically reduces the cost to manufacture the 3Dprinter for this particular use.

It should be understood that the proposed method and the associateddevices can be implemented in various forms of hardware, software,firmware, special processors or a combination thereof. Both theequipment disclosed herein as part of the projection modules and theremote, centralized controller host may be implemented accordingly.Thus, special processors may comprise Application-Specific IntegratedCircuits (ASICs), Reduced Instruction Set Computers (RISC) and/or FieldProgrammable Gate Arrays (FPGAs). Accordingly, the presently disclosedmulti-projector implemented additive manufacturing device and itsassociated functionality may be implemented as a combination of hardwareand software. The software may be installed as an application program ona program storage device. This typically involves a machine based on acomputer platform which has hardware, such as, for example, one or morecentral units (CPU), a random-access memory (RAM) and one or moreinput/output (I/O) interfaces. Furthermore, an operating system istypically installed on the computer platform. The different processesand functions that have been described here may form part of theapplication program, or a part which is run via the operating system.

Thus, in accordance with disclosed embodiments, a patterning module maybe provided for use in an additive manufacturing device as part of anarray of patterning modules under common control by a device controllerthat is remote to the patterning module array, wherein the patterningmodule includes a micro-projector configured to project energy forperforming energy patterning based on data received from the remotecontroller for the device, wherein positioning of the microprojector iscontrolled relative to micro-projectors included in other patterningmodules within the patterning module array based on the received data.

In accordance with those disclosed embodiments, the patterning modulemay optionally include a micro-computer coupled to the micro-projectorwhich receives the data from the remote controller for the device foremitting energy via the micro-projector to control the micro-projectorto emit energy based on the received instructions.

In accordance with those disclosed embodiments, the patterning modulemay optionally include the multi-axis, micro-positioning system coupledto the micro-computer and configured to control positioning of themicro-projector relative to micro-projectors included in otherpatterning modules within the patterning module array, wherein themicro-positioning system includes a plurality of actuators operatedbased on the data provided by the micro-positioning system, wherein suchdata are based on data received by the micro-positioning system from theremote device controller optionally via the micro-computer.

Likewise, in accordance with some disclosed embodiments, a patterningmodule for use in an additive manufacturing device as part of an arrayof patterning modules under common control by a device controller thatis remote to the patterning module array is provided, wherein thepatterning module includes a micro-projector configured to projectenergy for performing energy patterning, and a multi-axis,micro-positioning system to control positioning of the micro-projectorrelative to micro-projectors included in other patterning modules withinthe patterning module array, wherein the micro-positioning systemincludes a plurality of actuators operated based on data provided by theremote device controller.

In accordance with those disclosed embodiments, the patterning modulemay optionally include a micro-computer coupled to the micro-projectorand/or multi-axis, micro-positioning system which relays data receivedby the remote device controller to either the micro-projector ormulti-axis micro-positioning system.

Moreover, in accordance with each of those disclosed embodiments, thedata between the micro-computer and remote device controller areencrypted. For example, this may involve encryption of SVG strings sentto an address associated with the patterning module, wherein theencryption is optionally performed by applying a symmetric encryptioncypher, encryption performed by applying one or more cypher keys ortokens specific to the additive manufacturing device, and/or encryptionthat scrambles x-y image plane data and encrypted data based uponbuffering frequency/speed, thereby scrambling the z-image stack data.

Further, in accordance with each of those disclosed embodiments, themulti-axis, micro-positioning system may automatically controlpositioning of the micro-projector relative to micro-projectors includedin other patterning modules within the patterning module array so as toautomatically align fields-of-view for the micro-projectors of thepatterning module array to generate a continuous display area.

Additionally, in accordance with each of those disclosed embodiments, asensory element collects data used to determine the relative location ofthe patterning modules to provide alignment of the field of view of themicro-projector with a micro-projector of at least one other patterningmodule in the array.

Further, in accordance with each of those disclosed embodiments, thecontrol of the multi-axis, micro-positioning system may optionally beperformed using a feed-back loop that includes the micro-projectorand/or the micro-positioner.

Moreover, in accordance with each of those disclosed embodiments, thedata received by micro-computer from the remote controller may includepositional commands for the multi-axis micropositioner and/or a data setto be projected by the micro-projector.

Referring now to FIGS. 13-18 , an additive manufacturing device and/orsystem is shown similar to that already discussed above, and thedisclosure of devices, systems, and methods mentioned above are equallyapplicable to the devices, systems, and methods discussed hereafter. InFIG. 13 , a patterning module 1100 is shown including a micro-projector,micro-computer, and actuators (x, y, and z) comprising stepper motorsfor driving precision motion of the positions of the micro-projector.Referring to FIGS. 14 and 15 , the stepper motors are arranged totranslate the frame supports of the module along guide rails that areoriented along the corresponding x, y, and z axes to position themicro-projector. Limit switches may be provided to guide operationalcontrol of the stepper motors by the micro-computer according to theremote host computer. Referring now to FIG. 16 , each module 1000illustratively includes one or more control boards 1112 for actuation ofthe actuators. The control boards 1112 may be operated under guidance ofthe micro-computer.

Referring now to FIGS. 18 and 19 , the additive manufacturing system isshown to include a base mount 1140. The base mount 1140 isillustratively embodied as a mounting plate for receiving connection ofthe patterning modules 1100. The base mount 1140 is illustrativelyformed as a structural member providing support for load bearingoperation of the actuators while accommodating selective arrangement ofthe modules 1100 for mounting. As shown in FIG. 18 , the patterningmodule 1100 is shown having one (longitudinal) end mounted to the basemount 1140. The one end of the module 1100 mounted to the base mount1140 is illustratively opposite the end having the micro-projector. Thebase mount 1140 illustratively includes guides 1142 illustrativelyembodied as alignment pins for insertion within alignment holes withinthe mounted patterning module 1100 to assist in proper mounting. In someembodiments, arrangement of one or more alignment pins may be formed onthe modules 1100 and the corresponding one or more alignment holes onthe base mount 1140. The base mount 1140 illustratively includesconnectors 1144. Connectors 1144 are illustratively embodied to providewired electrical communication between the host computer and themicro-computer of the pattern module 1100. In the illustrativeembodiment, the connectors 1144 provide electrical connection forelectrical power and data communication. In some embodiments, theconnectors 1144 may be configured to provide wired electrical power, anddata may be communicated wirelessly with the modules 1100. Thepatterning module 1100 is connected with the corresponding connector1144 via a matching connector 1146 of the patterning module 1100. Powersupply circuitry may be mounted on the base mount 1140.

Referring now to FIG. 19 , four patterning modules 1140 are shownmounted to the base mount 1140. Each patterning module 1140 is arrangedin communication with the corresponding connector 1144 via its matchingconnector 1146. Accordingly, a modular array can be formed withselectively arrangeable modules 1140 that can be easily connected anddisconnected for mounting in a variety of positions to provide thedisplay area suitable for the build project.

Within the present disclosure, a patterning module for an additivemanufacturing system as part of an array of patterning modules undercommon control by a controller that is remote to the array of patterningmodules, may include a micro-projector configured to project energy forperforming energy patterning for additive manufacturing; and amulti-axis micro-positioning system to control positioning of themicro-projector relative to micro-projectors of other patterning moduleswithin the array of patterning modules. The micro-positioning system mayinclude a plurality of actuators operated based on patterning dataprovided by the remote controller.

In some embodiments, the multi-axis micro-positioning system mayimplement positioning of the micro-projector relative tomicro-projectors of other patterning modules of the array to alignfields-of-view for the micro-projectors of the array to generate acontinuous display area. The multi-axis micro-positioning system mayimplement positioning of the micro-projector according to automatedcontrol commands from the remote controller to automatically align afield-of-view of the micro-projector with at least one field-of-view ofthe other patterning modules of the array.

In some embodiments, the remote controller may be arranged incommunication with at least one sensor for collecting data to determinea relative position of one or more of the other patterning modules foraligning the field of view of the micro-projector with themicro-projector of at least one other patterning module of the array.Automated control commands for the multi-axis micro-positioning systemmay be generated by the remote controller using feed-back controlinformation considering at least one of the micro-projector and themicro-positioning system. Although in some embodiments, any suitablemanner of control scheme may be applied including derivative, feedforward controls, and/or combinations thereof.

In some embodiments, the patterning module may further include amicro-computer. The micro-computer may be arranged in communication withat least one of the micro-projector and the multi-axis micro-positioningsystem. The micro-computer may be arranged for receiving controlcommands including the patterning data from the remote controller forcontrolling operation of at least one of the micro-projector and themulti-axis micro-positioning system.

In some embodiments, the patterning data received by micro-computer fromthe remote controller may include positional commands for the multi-axismicropositioner. The patterning data may includes a projection data setto be projected by the micro-projector for additive manufacturing. Thepatterning data may include synchronization data for synchronizing thetiming of the modules of the array. For example, the synchronizationdata may include a clock signal and/or may be formed digitally and/or byanalog signal.

In some embodiments, communications between the micro-computer andremote controller may be encrypted. Encryption of the communicationsbetween the micro-computer and the remote controller may includeencryption of vector strings sent to an address associated with thepatterning module. Encryption may include application of symmetricencryption cypher. In some embodiments, encryption may includeapplication of cypher keys and/or tokens specific to the additivemanufacturing system. Encryption may include scrambling of at least oneof x-y image plane data and z-image stack based upon at least one ofdata buffering frequency and data transmission speeds.

Within the present disclosure, an additive manufacturing device mayinclude a device controller; and an array of patterning modules undercommon control of the device controller, wherein the device controlleris arranged remote relative to the patterning module array. By beingremote, the device controller may be nearby but distinct from themodules to allow preferable physical arrangement of the modules, whilehaving central control. In some embodiments, each of the patterningmodules within the array may include a micro-projector configured toproject energy for performing energy patterning for additivemanufacturing. One or more of the patterning modules may include amulti-axis micro-positioning system to control positioning of themicro-projector relative to micro-projectors of other patterning modulesof the array of patterning modules. The one or more micro-positioningsystems may include a plurality of actuators operated based onpatterning data provided by the device controller.

In some embodiments, each patterning module may further include amicro-computer in communication with at least one of the correspondingmicro-projector and multi-axis micro-positioning system. Eachmicro-computer may be arranged for receiving control commands includingthe patterning data from the remote controller for controlling operationof at least one of the corresponding micro-projector and multi-axismicro-positioning system.

In some embodiments, the multi-axis micro-positioning system mayimplement positioning of one or more of the micro-projectors relative toat least one micro-projector of other patterning modules of the array toalign fields-of-view for the micro-projectors of the array to generate acontinuous display area. The multi-axis micro-positioning system mayimplement positioning of the one or more micro-projectors according toautomated control commands from the remote controller to automaticallyalign fields-of-view for the micro-projectors of the array.

In some embodiments, the additive manufacturing device may furthercomprising at least one sensor for collecting data. The at least onesensor may be arranged in communication with the device controller fordetermining relative location of one or more of the patterning modulesfor aligning one or more fields-of-view of the micro-projectors of thearray.

In some embodiments, automated control commands for the multi-axismicro-positioning system may be generated by the remote controller. Theremote control may generate automated control commands using feed-backcontrol information considering at least one of the micro-projector andthe micro-positioning system. Although in some embodiments, any suitablecontrol manner may be implemented including derivative, feed-forward,and/or combinations thereof.

In some embodiments, the patterning data received by at least onemicro-computer from the remote controller may include positionalcommands for the multi-axis micropositioner. The patterning data mayinclude a projection data set to be projected by the micro-projector.The patterning data may include synchronization data for synchronizingprojection between different modules of the array.

In some embodiments, the communications between one or more of themicro-computers and remote device controller may be encrypted.Encryption may include encryption of vector strings sent to an addressassociated with the patterning module. Encryption may includeapplication of symmetric encryption cypher. Encryption may includeapplication of cypher keys and/or tokens specific to the additivemanufacturing system. Encryption may include scrambling of at least oneof x-y image plane data and z-image stack based upon at least one ofdata buffering frequency and data transmission speeds.

In some embodiments, the additive manufacturing device may furtherinclude a base mount configured to receive mounting of one or morepatterning modules of the array. The base mount may include a number ofconnection ports to provide power and/or communication. Each connectionport may be configured for communication with one of the patterningmodules mounted on the base mount to provide communication with theremote controller to provide power and/or communication.

Within the present disclosure, a method of performing additivemanufacturing may include controlling emission of projected energy by anarray of a plurality of patterning modules by a device controller. Thedevice control may be remote to the patterning module array. Each of thepatterning modules within the array may include a micro-projectorconfigured to project energy for performing energy patterning. Themethod may include controlling positioning of the micro-projectorrelative to micro-projectors included in other patterning modules withinthe patterning module array using a multi-axis, micro-positioningsystem, wherein the micro-positioning system includes a plurality ofactuators operated based on instructions provided by the remote devicecontroller.

In some embodiments, the method may further comprise relaying datareceived from the remote device controller by a micro-computer coupledto the micro-projector and/or the multi-axis, micro-positioning systemto either the micro-projector or multi-axis micro-positioning system. Insome embodiments, the method may further comprise encrypting the datasent between the micro-computer and remote device controller. In someembodiments, the multi-axis, micro-positioning system may automaticallycontrols positioning of the micro-projector relative to micro-projectorsincluded in other patterning modules within the patterning module arrayso as to automatically align fields-of-view for the micro-projectors ofthe patterning module array to generate a continuous display area.

In some embodiments, the method may further comprise collecting datausing a sensory element to determine the relative location of thepatterning modules to provide alignment of the field of view of themicro-projector with a micro-projector of at least one other patterningmodule in the array. In some embodiments, control of the multi-axis,micro-positioning system may be performed using a feed-back loop thatincludes the micro-projector and/or the micro-positioner.

The disclosure is not limited to the example embodiments described here.There is scope for various adaptations and modifications which theperson skilled in the art, due to his technical knowledge, would alsoconsider as belonging to the disclosure.

1. A patterning module for an additive manufacturing system as part ofan array of patterning modules under common control by a controller thatis remote to the array of patterning modules, the patterning modulecomprising: a micro-projector configured to project energy forperforming energy patterning for additive manufacturing; and amulti-axis micro-positioning system to control positioning of themicro-projector relative to micro-projectors of other patterning moduleswithin the array of patterning modules, wherein the micro-positioningsystem includes a plurality of actuators operated based on patterningdata provided by the remote controller.
 2. The patterning module ofclaim 1, wherein the multi-axis micro-positioning system implementspositioning of the micro-projector relative to micro-projectors of otherpatterning modules of the array to align fields-of-view for themicro-projectors of the array to generate a continuous display area. 3.The patterning module of claim 2, wherein the multi-axismicro-positioning system implements positioning of the micro-projectoraccording to automated control commands from the remote controller toautomatically align a field-of-view of the micro-projector with at leastone field-of-view of the other patterning modules of the array.
 4. Thepatterning module of claim 3, wherein the remote controller is arrangedin communication with at least one sensor for collecting data todetermine a relative position of one or more of the other patterningmodules for aligning the field of view of the micro-projector with themicro-projector of at least one other patterning module of the array. 5.The patterning module of claim 3, wherein automated control commands forthe multi-axis micro-positioning system are generated by the remotecontroller using feed-back control information considering at least oneof the micro-projector and the micro-positioning system.
 6. Thepatterning module of claim 1, further comprising a micro-computerarranged in communication with at least one of the micro-projector andthe multi-axis micro-positioning system for receiving control commandsincluding the patterning data from the remote controller for controllingoperation of at least one of the micro-projector and the multi-axismicro-positioning system.
 7. The patterning module of claim 6, whereinthe patterning data received by micro-computer from the remotecontroller includes positional commands for the multi-axismicropositioner.
 8. The patterning module of claim 6, wherein thepatterning data received by micro-computer from the remote controllerincludes a projection data set to be projected by the micro-projectorfor additive manufacturing.
 9. The patterning module of claim 6, whereincommunications between the micro-computer and remote controller areencrypted.
 10. The patterning module of claim 9, wherein encryption ofthe communications between the micro-computer and the remote controllerincludes encryption of vector strings sent to an address associated withthe patterning module.
 11. The patterning module of claim 10, whereinencryption includes application of symmetric encryption cypher.
 12. Thepatterning module of claim 9, wherein encryption includes application ofone or more of cypher keys and token specific to the additivemanufacturing system.
 13. The patterning module of claim 9, whereinencryption includes scrambling of at least one of x-y image plane dataand z-image stack based upon at least one of data buffering frequencyand data transmission speeds. 14.-29. (canceled)
 30. The patterningmodule of claim 1, wherein the patterning data includes data forsynchronizing projection between patterning modules of the array. 31.The patterning module of claim 1, wherein the field of view of thepatterning module is larger than a footprint of the patterning module.32. (canceled)
 33. A method of performing additive manufacturingcomprising: controlling emission of projected energy by an array of aplurality of patterning modules by a device controller that is remote tothe patterning module array, wherein each of the patterning moduleswithin the array includes a micro-projector configured to project energyfor performing energy patterning; and controlling positioning of themicro-projector relative to micro-projectors included in otherpatterning modules within the patterning module array using amulti-axis, micro-positioning system, wherein the micro-positioningsystem includes a plurality of actuators operated based on instructionsprovided by the remote device controller.
 34. The method of claim 33,further comprising relaying data received from the remote devicecontroller by a micro-computer coupled to the micro-projector and/or themulti-axis, micro-positioning system to either the micro-projector ormulti-axis micro-positioning system.
 35. The method of claim 34, furthercomprising encrypting the data sent between the micro-computer andremote device controller.
 36. The method of claim 35, wherein themulti-axis, micro-positioning system automatically controls positioningof the micro-projector relative to micro-projectors included in otherpatterning modules within the patterning module array so as toautomatically align fields-of-view for the micro-projectors of thepatterning module array to generate a continuous display area.
 37. Themethod of claim 36, further comprising collecting data using a sensoryelement to determine the relative location of the patterning modules toprovide alignment of the field of view of the micro-projector with amicro-projector of at least one other patterning module in the array.38. The method of claim 36, wherein the control of the multi-axis,micro-positioning system is performed using a feed-back loop thatincludes the micro-projector and/or the micro-positioner.